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Hydroforming
Process Holds Critical Thickness in Manufacturing of Float Parts
Industry:
Manufacturing
Situation:
An Oklahoma manufacturer
of stainless steel floats experienced problems with the stamped
and spun parts they purchased from another vendor. The pieces were
fabricated from 18 gauge stainless steel, which is .048" thick.
Both the stamping and spinning processes were thinning the material
to .035", causing the floats to explode under pressure. The
continued failure of the parts to pass the required ten minute 600
psi test, even after costly tooling changes, was frustrating and
expensive. The company was reluctant to expend more on tooling without
being certain of a solution.
Solution:
The manufacturer
contacted Metalspun and was intrigued to learn that the hydroforming
process would maintain the material thickness of the float components,
enabling the parts to withstand high pressure and pass the quality
tests. However, they were unwilling to spend even more money on
tooling only to achieve the same results their other suppliers provided.
Metalspun understood
their hesitation and offered to front the initial tooling cost until
a superior part was produced that would exceed the required tests.
After a few sample exchanges, Metalspun decided to substitute a
lighter 19 gauge stainless for the original 18 gauge. In addition,
a step was spun on the float halves to add strength and serve as
a mating guide for welding. The hydroforming process held the thickness
within .002" throughout the run and the thinner material decreased
the weight, resulting in even greater cost savings. The new hydroformed
and spun floats easily passed the pressurized test. Metalspun's
creative approach produced exceptional parts, and repeat orders.
Bottom Line:
Metalspun met
the Oklahoma company's challenge. Not only did the floats surpass
the pressurized test, but the customer saved money by using a lighter
material. Welding time was also reduced by adding the spun step,
which mated the parts with ease, and added extra strength to the
completed part. This is only one of the many instances that confirm
that hydroforming and spinning are a winning combination.
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